K20A2, K20Z1 Engines

Intake Manifold Removal and Installation

Intake Manifold - K20A2, K20Z1 Engines:

Removal
1. Relieve fuel pressure.





2. Remove the intake manifold cover.





3. Remove the EVAP canister hose (A), brake booster vacuum hose (B), and vacuum hoses (C).





4. Disconnect the IAT sensor connector (A), and remove the breather hose (B), then remove the air cleaner housing (C).





5. Fully open the throttle link and cruise control link by hand, then remove the throttle cable (A) and cruise control actuator cable (B) from the links. Loosen the locknuts (C), and remove the cables from the bracket.





6. Remove the water bypass hoses, then plug the water bypass hoses.
7. Remove the fuel feed line.





8. Remove the PCV hose (A), harness holder mounting bolt (B), and harness clamp mounting bolt (C).
9. Remove the engine wire harness connectors and wire harness clamps from the intake manifold.
^ Four injector connectors
^ IAC valve connector
^ TP sensor connector
^ MAP sensor connector
^ EVAP canister purge valve connector





10. Remove the two bolts securing the intake manifold and brackets.





11. Remove all the intake manifold mounting bolts/nuts (A).
12. Remove the two stud bolts (B), then remove the intake manifold (C).

Installation





1. Install the intake manifold (A) with anew gasket (B), then tighten the two stud bolts (C).
2. Tighten all intake manifold mounting bolts/nuts (D) in a crisscross pattern in two or three steps, beginning with the inner bolt.





3. Tighten the two bolts securing the intake manifold and brackets.





4. Install the PCV hose (A), harness holder mounting bolt (B), and harness clamp mounting bolt (C).
5. Install the fuel feed line.





6. Install the water bypass hoses.
7. Install the throttle cable, then adjust it.
8. Install the cruise control actuator cable, then adjust it.





9. Install the air cleaner housing (A) and connect the IAT sensor connector (B).
10. Install the breather hose (C).





11. Install the EVAP canister hose (A), brake booster vacuum hose (B), and vacuum hoses (C).





12. Install the intake manifold cover.
13. After installation, check that all tubes, hoses, and connectors are installed correctly.
14. Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starter) so that the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
15. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
16. Clean up any spilled engine coolant.